Glass Core Clamp Structure for Edge Crack and Delamination Control
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Solution Overview
Problem
Glass core panels are prone to breaking during handling and mechanical processing due to their brittle nature, and existing solutions for embedding them in organic frames lead to issues like gap interface cracking and debonding, especially in thin core applications.
Innovation Solution
A core layer structure is proposed that includes a dielectric layer encapsulating a glass sheet, with conductive pathways and a clamp structure that connects through-vias to provide structural support, enhancing the bond between the glass and the organic frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If glass core panels are embedded in organic frames through reconstitution process, then the glass edges are protected from direct contact with processing toolsets, but gap interface cracking and debonding occur due to increased warpage and reduced stiffness
Solution Approach 1:
The clamp structure is divided into multiple segments including top clamp portions, bottom clamp portions, and intermediate clamp portions that can independently engage with the glass core panel. This segmentation allows each clamp segment to provide localized support and distribute mechanical stresses, preventing gap interface cracking and debonding while maintaining edge protection during processing operations.
Solution Approach 2:
The clamp structure combines rigid materials (such as metal or rigid polymer) with flexible elements to create a composite clamping mechanism. This composite construction provides the necessary stiffness to prevent warpage and debonding while maintaining the ability to accommodate thermal expansion and contraction during processing, thereby resolving the contradiction between edge protection and interface reliability.
2Ease of operation
If glass core panels are embedded in organic frames, then handling is facilitated through the frame, but the glass sheets become prone to breaking due to their brittle nature
Solution Approach 1:
The clamp structure is pre-positioned and engaged with the glass core panel before the reconstitution process begins. This preliminary action ensures that the glass sheets are securely held and supported throughout subsequent handling and processing operations, preventing breakage while allowing the organic frame to facilitate easy handling and manipulation of the entire assembly.
Solution Approach 2:
The clamp structure serves as an intermediary mechanical element between the processing toolsets and the brittle glass core panel. It provides a robust interface for handling and processing operations, absorbing and distributing mechanical stresses to protect the glass sheets from breaking while enabling effective manipulation through the organic frame structure.
3Manufacturing precision
If thin core processing is performed with embedded glass, then manufacturing precision is improved, but delamination occurs due to reduced stiffness
Solution Approach 1:
The clamp structure applies localized clamping forces at specific regions of the glass core panel, particularly at the edges and interfaces where delamination is most likely to occur. This local quality approach provides enhanced support and stability at critical locations while maintaining the thin core profile, preventing delamination between the glass and encapsulation material during precision processing operations.
Solution Approach 2:
The clamp structure dynamically adjusts its clamping parameters (such as clamping force and engagement position) based on the specific processing requirements and material properties. This parameter adjustment capability allows the system to maintain optimal stability and prevent delamination during thin core processing while preserving manufacturing precision and enabling high-volume production of glass-containing panels.
Data Source
AI summary
A core layer of a package substrate includes a dielectric layer; a glass sheet encapsulated in the dielectric layer; and a clamp structure including a through-via extending through the sheet, a top plate structure connected to a top end of the through-via, and a bottom plate structure connected to a bottom end of the through-via, wherein one of: the top plate structure and the bottom plate structure have respective lateral end surfaces that are substantially flush with a lateral edge surface of the core layer; or the through-via is a first through-via, the core layer includes a block at an edge region thereof that defines an interface with the dielectric layer and includes an organic material, the clamp structure includes a second through-via extending through the block, the top plate structure is connected to top ends of respective ones of the first through-via and the second through-via, and the bottom plate structure is connected to bottom ends of respective ones of the first through-via and the second through-via.